Electronics enclosure with heat-transfer element

ABSTRACT

A compressor may include a compressor shell, a motor, a compression mechanism, an enclosure, a control module, a fan, and an airflow deflector. The compression mechanism is disposed within the compressor shell. The motor drives the compression mechanism. The enclosure defines an internal cavity. The control module is in communication with the motor and is configured to control operation of the motor. The fan may be disposed within the internal cavity. The airflow deflector may include a base portion, a first leg, and a second leg. The first and second legs may be spaced apart from each other and may extend from the base portion. The fan may force air against the base portion. A first portion of the air may flow from the base portion along the first leg, and a second portion of the air may flow from the base portion along the second leg.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/935,786 filed on Jul. 22, 2020, which claims the benefit of U.S.Provisional Application No. 62/878,497 filed on Jul. 25, 2019. Theentire disclosures of the above applications are incorporated herein byreference.

FIELD

The present disclosure relates to an electronics enclosure with aheat-transfer element.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Electronic components, such as control modules for a compressor, forexample, generate heat during operation. Such electronic components areoften housed in sealed enclosures that protect the electronic componentsfrom exposure to moisture, dirt, and debris. A fan can be providedwithin the enclosure to facilitate heat transfer between the electroniccomponents and air within the enclosure. Heat can then be transferredfrom the air to the walls of the enclosure, and subsequently to theambient atmosphere, for example. The present disclosure provides anenclosure for electronic components and includes features for improvingairflow within the enclosure to improve cooling of the electroniccomponents.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In one form, the present disclosure provides a compressor that mayinclude a compressor shell, a compression mechanism disposed within thecompressor shell, a motor disposed within the shell and driving thecompression mechanism, and a control module in communication with themotor and configured to control operation of the motor. An enclosure maybe mounted to the compressor shell and may define an internal cavity inwhich the control module may be disposed. A fan may be disposed withinthe internal cavity. The enclosure may include an airflow deflectorhaving a base portion, a first leg, and a second leg. The first andsecond legs may be spaced apart from each other and extend from the baseportion. The fan may force air against the base portion. A first portionof the air may flow from the base portion along the first leg. A secondportion of the air may flow from the base portion along the second leg.

In some configurations of the compressor of the above paragraph, theairflow deflector is integrally formed with a shell member that definesthe enclosure. In some configurations, the airflow deflector is a recessformed in the shell member.

In some configurations of the compressor, the airflow deflector isformed separately from a shell member that defines the enclosure. Insome configurations, the airflow deflector is mounted to the shellmember.

In some configurations of the compressor of any of the above paragraphs,the base portion and the first and second legs cooperate to form aU-shape.

In some configurations of the compressor of any of the above paragraphs,the fan is aligned with the base portion such that a rotational axis ofthe fan extends through the base portion.

In some configurations of the compressor of any of the above paragraphs,the first and second legs include curved surfaces.

In some configurations of the compressor of any of the above paragraphs,air flows from the fan toward the base portion in a first direction.

In some configurations of the compressor of any of the above paragraphs,the curved surfaces of the first and second legs curve in a seconddirection as the curved surfaces extend away from the base portion.

In some configurations of the compressor of any of the above paragraphs,the second direction is opposite the first direction.

In another form, the present disclosure provides an assembly that mayinclude a shell, an electronic component, a fan, and an airflowdeflector. The shell member may at least partially define an enclosurehaving an internal cavity. The electronic component may be disposedwithin the internal cavity. The fan may be disposed within the internalcavity. The airflow deflector may include a base portion, a first leg,and a second leg. The first and second legs may be spaced apart fromeach other and extend from the base portion. The fan may force airagainst the base portion. A first portion of the air may flow from thebase portion along the first leg. A second portion of the air may flowfrom the base portion along the second leg.

In some configurations of the assembly of the above paragraph, theairflow deflector is integrally formed with the shell member.

In some configurations of the assembly of either of the aboveparagraphs, the airflow deflector is a recess formed in the shellmember.

In some configurations, the airflow deflector is formed separately fromthe shell member and is mounted to the shell member.

In some configurations of the assembly of any of the above paragraphs,the base portion and the first and second legs cooperate to form aU-shape.

In some configurations of the assembly of any of the above paragraphs,the fan is aligned with the base portion such that a rotational axis ofthe fan extends through the base portion.

In some configurations of the assembly of any of the above paragraphs,the first and second legs include curved surfaces.

In some configurations of the assembly of any of the above paragraphs,air flows from the fan toward the base portion in a first direction.

In some configurations of the assembly of any of the above paragraphs,the curved surfaces of the first and second legs may curve in a seconddirection as the curved surfaces extend away from the base portion.

In some configurations of the assembly of any of the above paragraphs,the second direction is opposite the first direction.

In some configurations of the assembly of any of the above paragraphs,the electronic component is disposed adjacent the base portion andbetween the first and second legs.

In some configurations of the assembly of any of the above paragraphs,the electronic component is, includes or is a part of a control moduleconfigured to control operation of a compressor.

In some configurations of the assembly of any of the above paragraphs,the enclosure is mounted to a shell of the compressor.

In some configurations of the assembly of any of the above paragraphs, adepth of the airflow deflector and an angle of attack of the first andsecond legs are configured to optimize airflow within the enclosure.

In some configurations of the assembly of any of the above paragraphs,the cavity is sealed such that air does not flow into or out of thecavity.

In some configurations of the assembly of any of the above paragraphs,the shell member may include heat sink fins. The fins may be formed onan exterior surface of the shell member.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a compressor including a control moduleand an enclosure in which the control module is housed;

FIG. 2 is a perspective view of the enclosure;

FIG. 3 is a cross-sectional view of the enclosure and control moduletaken along line 3-3 of FIG. 2 ;

FIG. 4 is a partial perspective view of an interior of a shell member ofthe enclosure;

FIG. 5 is a plan view of an exterior of the shell member;

FIG. 6 is a perspective view of an alternative enclosure for housing thecontrol module;

FIG. 7 is a cross-sectional view of the enclosure and control moduletaken along line 7-7 of FIG. 6 ;

FIG. 8 is a perspective view of an airflow deflector and fan of theenclosure of FIG. 6 ;

FIG. 9 is an exploded perspective view of the airflow deflector and fan;and

FIG. 10 is a plan view of the enclosure of FIG. 6 .

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

With reference to FIG. 1 , a compressor 10 is provided that may beoperable to compress a working fluid (e.g., a refrigerant) and circulatethe working fluid throughout a vapor compression circuit of aclimate-control system (e.g., a refrigeration or air conditioningsystem). The compressor 10 includes a control module 12 disposed withinan enclosure 14. The control module 12 may include processing circuitry(e.g., a circuit board) and other electronic components and may beoperable to control operation of the compressor 10 and/or diagnosecompressor faults. For example, the control module 12 may be avariable-speed drive for controlling a motor 13 of a variable-speedcompressor. The motor 13 may drive a compression mechanism 15 of thecompressor 10 (e.g., via a driveshaft). For example, the compressionmechanism 15 may be a scroll compression mechanism (including a pair ofinterleaving scrolls), a reciprocating compression mechanism (includingone or more pistons and cylinders), a rotary vane compression mechanism(including a rotor and cylinder), or any other type of compressionmechanism. The enclosure 14 may house the control module 12 and can bemounted to a shell 16 of the compressor 10.

Referring now to FIGS. 2-5 , the enclosure 14 will be described indetail. The enclosure 14 may include a first shell member 18 (FIGS. 2-5) and a second shell member 20 (FIG. 3 ) that cooperate to define asealed internal cavity 22 (FIG. 3 ) in which the control module 12 isdisposed. The first and second shell members 18, 20 can be fixed to eachother by bolts or other fasteners, for example.

A fan 24 may be disposed within the cavity 22 and is operable tocirculate air around the cavity 22 to convectively cool the controlmodule 12. The fan 24 may be attached to or mounted proximate an airflowdeflector (or airfoil) 26. In the particular example shown in FIGS. 2-5, the airflow deflector 26 is integrally formed in the first shellmember 18. In some configurations, heat sink fins may be formed onexterior surfaces of the first shell member 18 and/or the second shellmember 20.

As shown in FIG. 4 , the airflow deflector 26 may be a generallyU-shaped scoop or recess formed in an interior surface 28 of the firstshell member 18. The airflow deflector 26 may include a base portion 30,a first leg 34, and a second leg 36. The first and second legs 34, 36may be spaced apart from each other and may extend from the base portion30. The first and second legs 34, 36 may define first and second airflowpaths, respectively. That is, the fan 24 may force air against the baseportion 30 between the first and second legs 34, 36, and a first portionof that air may flow through the first airflow path along the first leg34 and a second portion of the air may flow through the second airflowpath along the second leg 36. From the first and second legs 34, 36, theair may flow throughout the internal cavity 22 of the enclosure 14 tocool the control module 12.

As shown in FIG. 3 , the base portion 30 of the airflow deflector 26 mayhave a depth D. The depth D may be a distance (measured along orparallel to a rotational axis R of the fan 24) between the fan 24 and abase portion 30 of the airflow deflector 26. A base surface 32 of eachof the first and second legs 34, 36 may be disposed at an angle ofattack A (e.g., an angle between the base surface 32 and the rotationalaxis R). The base surfaces 32 of the first and second legs 34, 36 can becurved or sloped. The depth D, angle of attack A, and any curve of slopeof the base surfaces 32 may be selected to maximize airflow velocitythrough the airflow deflector 26 and minimize a pressure drop of airflowing through the airflow deflector 26.

As shown in FIG. 5 , one or more electronic components 40 of the controlmodule 12 may be positioned between the first and second legs 34, 36 andadjacent the base portion 30. Such positioning may enhance the coolingof the components 40. For this reason, in some configurations, thecomponent(s) 40 selected to be positioned between first and second legs34, 36 may be components that tend to generate the most heat and/or needthe most cooling.

Referring now to FIGS. 6-10 , an alternative enclosure 114 is providedthat can house the control module 12. The enclosure 114 may include afirst shell member 118, a second shell member 120, and a fan 124. Thefirst and second shell members 118, 120 and fan 124 be similar oridentical to the shell members 18, 20 and fan 24 described above, exceptthat the first shell member 118 does not include an integrally formedairflow deflector. Instead, the enclosure 114 includes a separateairflow deflector (or airfoil) 126 that may be mounted to the firstshell member 118.

Like the airflow deflector 26, the airflow deflector 126 may begenerally U-shaped and may include a base portion 130, a first leg 134,and a second leg 136. As shown in FIG. 7 , the base portion 130 of theairflow deflector 126 may have a depth D. The depth D may be a distance(measured along or parallel to a rotational axis R of the fan 124)between the fan 124 and a base portion 130 of the airflow deflector 126.A base surface 132 of each of the first and second legs 134, 136 may bedisposed at an angle of attack A (e.g., an angle between the basesurface 132 and the rotational axis R). The base surfaces 132 of thefirst and second legs 134, 136 can be curved or sloped. The depth D,angle of attack A, and any curve of slope of the base surfaces 132 maybe selected to maximize airflow velocity through the airflow deflector126 and minimize a pressure drop of air flowing through the airflowdeflector 126.

The airflow deflectors 26, 126 of the enclosures 14, 114 may improveairflow throughout the interior of the enclosures 14, 114 and around thecontrol module 12. Furthermore, the airflow deflectors 26, 126 mayreduce or eliminate turbulence in the airflow, which improves heattransfer between the control module 12 and the air within the enclosure14, 114.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. An assembly comprising: a compressor including acompressor shell, a compression mechanism disposed within the compressorshell, and a motor driving the compression mechanism; an enclosurephysically connected to the compressor and defining an internal cavity;a control module in communication with the compressor and configured tocontrol operation of the compressor; a fan disposed within the internalcavity; and an airflow deflector having a base portion, a first leg, anda second leg, wherein the first and second legs are spaced apart fromeach other and extend from the base portion, wherein the fan forces airagainst the base portion, wherein a first portion of the air flows fromthe base portion along the first leg, and wherein a second portion ofthe air flows from the base portion along the second leg.
 2. Theassembly of claim 1, wherein the airflow deflector is integrally formedwith a shell member that defines the enclosure.
 3. The assembly of claim2, wherein the airflow deflector is a recess formed in the shell member.4. The assembly of claim 1, wherein the airflow deflector is formedseparately from a shell member that defines the enclosure, and whereinthe airflow deflector is mounted to the shell member.
 5. The assembly ofclaim 1, wherein the control module is disposed within the internalcavity of the enclosure.
 6. The assembly of claim 1, wherein theenclosure is mounted to the compressor shell.
 7. The assembly of claim1, wherein the base portion and the first and second legs cooperate toform a U-shape, and wherein the fan is aligned with the base portionsuch that a rotational axis of the fan extends through the base portion.8. The assembly of claim 1, wherein the first and second legs includecurved surfaces, wherein the air flows from the fan toward the baseportion in a first direction, wherein the curved surfaces of the firstand second legs curve in a second direction as the curved surfacesextend away from the base portion, and wherein the second direction isopposite the first direction.
 9. The assembly of claim 1, wherein theinternal cavity is a sealed cavity.
 10. A compressor comprising: acompressor shell; a compression mechanism disposed within the compressorshell, a motor driving the compression mechanism; an enclosure definingan internal cavity; a control module in communication with the motor andconfigured to control operation of the motor; a fan disposed within theinternal cavity; and an airflow deflector having a base portion, a firstleg, and a second leg, wherein the first and second legs are spacedapart from each other and extend from the base portion, wherein the fanforces air against the base portion, wherein a first portion of the airflows from the base portion along the first leg, and wherein a secondportion of the air flows from the base portion along the second leg. 11.The compressor of claim 10, wherein the airflow deflector is integrallyformed with a shell member that defines the enclosure.
 12. Thecompressor of claim 11, wherein the airflow deflector is a recess formedin the shell member.
 13. The compressor of claim 10, wherein the airflowdeflector is formed separately from a shell member that defines theenclosure, and wherein the airflow deflector is mounted to the shellmember.
 14. The compressor of claim 10, wherein the enclosure isconnected to the compressor shell.
 15. The compressor of claim 14,wherein the enclosure is mounted to the compressor shell.
 16. Thecompressor of claim 10, wherein the base portion and the first andsecond legs cooperate to form a U-shape, and wherein the fan is alignedwith the base portion such that a rotational axis of the fan extendsthrough the base portion.
 17. The compressor of claim 10, wherein thefirst and second legs include curved surfaces, wherein the air flowsfrom the fan toward the base portion in a first direction, wherein thecurved surfaces of the first and second legs curve in a second directionas the curved surfaces extend away from the base portion, and whereinthe second direction is opposite the first direction.
 18. The compressorof claim 10, wherein a depth of the airflow deflector and an angle ofattack of the first and second legs are configured to optimize airflowwithin the enclosure.
 19. The compressor of claim 10, wherein thecontrol module is disposed within internal cavity of the enclosure. 20.The compressor of claim 10, wherein the internal cavity is a sealedcavity.